Process and apparatus for converting oil



Dec. 29, 1931. c. P. DUBBS PROCESS AND APPARATUS FOR CONVERTING' Original Filed March 30, 1921 124 Sheets-Sheet Dec. 29, 1931. c. P. DUBBS PROCESS AND APPARATUS FOR CONVERTING OIL sheets-sheet 2 Original Filed March 50, 1921 lo stored or may Patented Dec. 29, 1931 UNIT-ED sjjrArEs PATENT OFFICE-- CARBON r. DUBBS, or WILME'rfrE, ILLINOIS, ASsIeNoIt 'ro UNIVERSAL CIL PRODUCTSY COMPANY, or CHICAGO, ILLINOIS, A CORPORATION or SoU'rII DAKOTAv PROCESS AND APPARATUS FOR CONVERTING OIL Application led Batch 30, 11921, Serial No. 456,812. Renewed March 15, 1928.

f5 expansion 'chambers by its conversion in the chamber into a gas, thereby avoiding the necessity of the separate removal of the' carbon from the chamber; to provide a process in which the gas enerated may be collected and gbe directly used inthe system as ,fuel or for other purposes in the operation of the process with resulting economy in fuel, labor and` time; to provide a process which may be Operated continuously and one 15 which may be economically used to convert the oil by utilizing products otherwise drawn off as Waste orreguiring separate handling or treatment; to provide .an apparatus by means of Which-this process may be eectiveprocess and apparatus of ferred to.

Fig. 1 is a side elevation of the apparatus with parts omitted 'and parts in section.

Fig. 2 is a plan detail ofthe expansion .chambers and superheater.'

Fig. 3 is a modified form of expansion chamber which is used without a superheater as shownin Fig. 1.

Referring to the details as shown in the apparatus in Figs. -1 and 2-the raw oil from any convenient source is introduced through the inlet line 1 controlled by the valve 2 to the top of adephlegmator 3. This dephlegmator is of common type filled with fragments of broken materialV which serves to separate the oil as it courses down through the dephlegmator'and subject greater quantities of the oil vapors rising through the 4dephlegmator to the cooler raw oil medium. The dephlegmator is fitted with a pyrometer 4 or similar temperature recording means and a pressure gauge. The raw oil, with What condensate it may lcollect from the vapors arising in the dephlegmator, is drawn ofi:l

the character rethrouvh the line 6, whlch is controlled by avalve .This line directs the oil to a pump 8 or it may be by-passed through the line 9 regulated by the valve 10. In either case the charging stockpasses through a line 10a to ly carried out and, 1n general, to provide a bers 20, 21 and 22 respectivelyv These ex` pansion chambers are preferably vertical in form lined with refractory material as shown at 232 such as fireclay or fire brick. Each eX- panslon chamber is fitted with the residuum draw-oftn line 24 controlled by a valve 25. The chambers are identical in construction and are adapted to be cut into the system as desired by means of the valves 26, 27 and 28 in the lines 17, 18 and 19.

In the bottom of ea'ch of the chambers are fitted collapsible grates 29 operated b an adjusting handle 30. The function o' the alternate chambersis the operating of one as an expansion chamber While the other is being operated as a gas producer. Describing first the operation as an expansion chamber,the heated oil passing through the transfer line 14 is directed by the secondary connecting line 19 to the expansion chamber 22. As shown in Fig. 1, the chambers are heavily lagged as shown at 31 to prevent the loss of heat through radiation. From whichever expansion chamber may be in operation as a conversion chamber, the 'cracked oil vapors are released and riseinto the vapor draw-ofi1 lines 32. Each chamber is'fitted with a similar draw-OH line controlled by valves 33 connecting toa common header 34:. A single lead 35 controlled by a valve 36 dif rects the oil vapor to the bottom of the de phlegmator in which it is dephlegmated by being brought into intimate contact with the incoming raw oil. i The dephlegmated vapors pass out from the top dephlegmator through -theline 37 to-a water condenser 38, the disit `may be conducted to the gasometer 45 through the line 46 controlled by a valve 47.

The gasometer 42 has a lead 48 regulated by a valve 49 through which the incondensable the gas burner 13. The valves 51 and 52 are interposed in this line. An extension of the gas line 50 leads to the second gasometer 45 so that a mixture of incondensable gas and Water gas may be directed to the burner 13. This prior explanation of the cracking operation describes the pro'cess when using the chamber 22 as an expansion chamber, thev other two chambers 20 and 21 being cut out of the system by closing the valves 26 and 27 and the valves in the vapor draw-off lines.

Describing now the. mode of using the expansion chambers as as enerators, when a suiiicient collection o car on is obtained in one-oi:` the expansion chambers to cause it to be ineffective` as an expansion chamber, the chambers. the valves previously mentioned, simultaneous with t e cutting in of one of the other chambers. This chamber with the carbon deposition therein 'is then subjected to an air blast through the compressed air line 53. Air being supplied to the carbon, which is at high temperature, immediately causes the temperature in the expansion chamber to rise until it is at the proper temperature for the production of the desired gas. At this point steam is introduced through the steam line 54 and the air supply discontinued. Durlng .the introduction of the air the inert gases formed pass up through the expansion chamber and out through a duct 55 regulated by a valve 56. This duct leads into the bottom of a superheater 57 and durin the admission of air to the expansion cham er, which has now become a gas generator, the top vent pipe 58 of the superheater is opened by removal of the cap 59. As soon as the chamber or generator has reached the temperature necessary for the generation of gas, steam is introduced and the vent pipe 58 closed. It is understood during this mode of o ration that the valve 60 in the lower duct 61 1s closed. The water gas formed by the decomposition of the steam in contact with the incandescent carbon takes a similar course as that of the inert gases through the 'duct 55 and into the bottom of the superheater 57 where it may be enriched by the carburization with oil through the jet 62 and further addition of air through compressed air pines such as that shown at 63 positioned at various heights 'on the superheater. A pyrometer 64 is inserted into the superheater near its top to ascertain l the temperature4 of the gas in that region.

'I line 67 to the gasometer 45. A draw-ofi line 68 directs the water gas through a ump 69 to a header 70 from which .it may e intro'- 4to promote cracking and evaporation.

This chamber with the carbon fifieaamsv duced into the bottom of any one of the expansion chambers or gas generators through separate lines 71 controlled by valves 72. The gis may be introduced to the separate cham' rs only when they are being used as expansion chambers in the conversion of the oil to aid in keeping the carbon in suspension by agitating the residual product and also It also helps to control the porosity of coke or carbon burned in the chamber. When the carbon has collected to an amount that the introduction of the gas in the bottom of the chamber does not effectively reach the oil body, the valve 72 may be closed and the gas directed to an upper header 73 through a line 74 and introduced in the upper part of the chambers through lines 75 regulated by valves 76.

To return to the' production of the gas from the carbon-in one of the expansion chambers, when used as a gas producer or generator, as the steam is introduced to the lower portion of the chamberfused in this connection the heat taken up by the steam in its decomposition will rapidly cool' the carbon body. It is advisable for this reason toA introduce steam intermittently with air and at times reverse the passage of air and gas through lthe enerator in order to proe cure the most `eiicient operation. To accomplish this result, du llcate steam and air pipes 77 and 78 similarly arranged as the air and steam ipes 53 and 54 are positioned in the top of t e generator. To reverse the direction of the air and gas the valve 56 in the duct 55 is closed and air is introduced throughy the compressed air pi 78. The valve 60 in the duct 61 is at this time open and the cap 59 in the vent pipe 58 in the top of the superheater is then removed. When the carbon body has reached the propertemperature, which may be ascertained by suitable recording devices, the air is shut oi and steam introduced. During the introduction of the steam through line 77, the

cap 59 is replaced and the gas directed to'the someter 45, as ex lained. In both of the uc'ts 55 and 61, w ich have separate connections to each of the expansion chambers, are small vent lines 79 controlled by valves 80. By keepin an ignited llame burning at all times at t e top of the vent pipe 79, the operator is'able to ascertain the character of the gas produced in the generator. In producing gas in this manner where 4carbon is permitted to collect in a heavy, sludgy body, as it may under certain operating conditions in these expansion chambers;

high air pressure ma be used to penetrate n body, it may be advisable to place in the chambers quantlties of broken fragments of ceramic material to keep the carbon body in and steam more divided form and ermit` the passage of air reely therethrough. AIn the production of gas in this manner air is introduced when its need is indicated by' the temperature of the coke or carbon. Then when through the introduction of the airthe.

'temperature is raised to a proper point steam is -reintroduced to generate the gas.

In the modified form of construction shown in Fig. 3 the use of the superheater is omitted, the transferred liquidbeing introduced to the expansion chamber or as generator 81 through the inlet line 14. t will be understood that such chamber, shown at 81,

may be mounted in the system-in pairs or as three units as shown in Fig. 2, the connections to the system being similar to those in Fig. 1. The carbon will collect in the chamber and When'it is changed over to be used as a draw-olf line 88 controlled by the valve 89.v

generator, air is injected through the com-l pressed airline 82 controlled by valves 83 and 84. During the injection of the air through the bottom compressor pipe, the pressure tight cap 85 is removed as is also a'slidable valve cap 86. is shown by the' construction, the valve 85 serving to cover the top vent when the chamber is being used as an expansion chamber and is bolted to the top flanges of the chamber. These lianged portions are so built that the excessive heat from the gases will not contact with the acings of the flanged portions. l/Vhen the carbon in the chamber has been brought to the required temperature, the slidable cover 86 is pushed into place over the top of the generator eiectively preventing theescape of the generated gas. At this juncture superheated steam is introduced through the lower pipe 87 and the -air shut oil. The gas is directed out through the In reversing the travel of the air and gases in the gas generator the valve'84 isclosed and the air directed through the vertical line 92 to the-upper gas line 88. The valve 89 in-this line being open, the air is introduced into the upper part of the converter and as thefcap prevents its being short-circuited directly to the chimney the air passes down lthrough the carbon body and thence through the secondary flue 93 from which it is directed to the stack 94. When the carbon has been raised to the temperature necessary' to produce water gas', steam is then introduced through a suprheated steam jet 95 and the secondary flue 93 closed by a valve 96 therein. At this time the air-valve 83 inthe line-82 is closed -and the valve 84 opened simultaneously with the closing of the valve 89A and the opening of the valve 88. lThe travel of the steam through the heated carbon forms the combustible gas which passes out through Water tankand gasometer as shown in Fig,

The difference in the capsv 1. In this modified form of construction the superheater has been eliminated and the gas direlcted to a collecting tank or gasometer direct y.

Any liquid residual substance collecting in the expansion chambers during cracking operation may be eliminated by 24 controlled `by valves 25.

Through control of pressure and temperature conditions in the circulation of the .reflux from the system the deposit of the carbon may be localized in the expansion chamber and there conveniently used for conversion into gas without interruption of the process otherwise necessitated through the accumulation in the heating zone or elsewhere. The gas produced by the method herein set forth may befeither water gas, producer gas or inertgas or mixtures thereof according to the method of operation.

I claim'as my invention:

' 1. A process for converting oil, consisting in heating the oil to a cracking temperature in a heating zone, passing the'heated oil to alternate expansion chambers and there removingthe generated vapors, permitting the collection of carbon in the chamber used in the cracking system, subsequently cutting out a carbonized chamber and generating gas therein byl introduction of air and steam thereto, and simultaneously cutting into the cracking system one of the alternate expansion` chambers into which the oil is diverted and in introducing the gas produced from the lprecipitated carbon to assist in converting oil introduced to the system.

2. A process for convertingv oil, consisting in heating the oil to a cracking temperature in a heatlng zone, successively directing the oil to alternate expansion chambers, cutting Veach chamber from the cracking system when a'substantial'body of precipitated carbon has collected thereinv and4 simultaneously cutting in an alternate chamber, introducing air and steam to said isolated chamber to form Water gas, collecting said gas and returning it to the expansion chambersto assist in the conversionof oil introduced to said chambers.

' 3. A process for converting oil,.consisting in heating the oil to a cracking temperature in a heating zone, successively directing the draw-off lines oil to alternate expansion chambers, cutting each chamber from the cracking system when a substantial body of precipitated carbon has collected therein and simultaneously cutting in an alternate chamber, introducing air and steam to said isolated chamber to -form water gas, collecting said gas andthe incondensable hydrocarbon gas resultingfrom the cracking separately, returning the Water gas to th eX- pansion chambers and directing the hydrocarbon gas to the furnace.

4. A process for converting oil, consisting in heating the oil to a cracking temperature Yin a heating zone, successively directing the oil to alternate expansion chambers, cutting each chamber from the cracking system when a substantial body of precipitated carbon has collected therein and simultaneously cuttin in an alternate chamber, introducing air and steam to-said isolated chamber to form water gas, collecting said gas and the incondensable hydrocarbon gas resulting from the cracking separately, combining a portion of the gases and directing the mixture to the furnace, and returning regulated quantities of the Water gas to the expansion chamber being operated with the cracking system.

5. A combined cracking and gas producing process, consisting in heating petroleum oil to a cracking temperature in a heating zone, vaporizing the cracked oil in expansion chambers, adapted to be cut in and out of the chacking system, permitting the carbon to collect in an expansion chamber during cracking, in discontinuing the feeding of oil to said carbonized chamber, and in consuming the precipitated carbon therein by alternately introducing air and steam into said chamber, forming gases, and in introducing into the oil a portion of the gases so formed to assist in the conversion of the oil.

6. A combined cracking and gas producing process, consisting in heating petroleum oil to a cracking temperature in a heating zone, vaporizing the cracked oil in expension chambers adapted to be used one at a time under a reduced pressure, isolating a chamber when a substantial carbon body has precipitated therein from oil conversion, producing Water gas in said chamber by intermittent introductions of air and steam to said isolated chamber, while operating one .of the alternate chambersras an expansion chamber in the cracking system and in introducing gases thus produced into the oil to assist in the conversion of additional quantities thereof.

7. A combined cracking and gas producing process, ,consisting in maintaining a supply of petroleum oil under cracking conditions of heat and pressure in an enlarged conversion zone, in which carbon separated from the oil during the cracking reaction accumulates, in simultaneously producing gas from the carbon accumulation resulting from the conversion of oil in a second enlarged zone by injecting steam and air to the accumulated carbon in said second enlarged zone, i-n collecting such gas and in employing portions thereof to accelerate the conversion of the oil in said first enlarged zone, and in taking off chamber, means for maintaining the oil body in a second enlarged chamber after the accumulation of carbon in the irst enlarged chamber has become objectionable, means for injecting steam and air to the accumulated carbon 1n said first chamber to produce gas, means for introducing predetermined portions of the gas so produced to the oil in said second enlarged chamber, means for collecting the remaining ortions of the gas, and means for taking ofi) the products of oil conversion from each of said enlarged chambers.

CARBON P. DUBBS.

converted constituents of the oil from said first enlarged Zone. n K 8. An apparatus for cracking oil and producing gas, comprising means for maintain- 

